Aco Polymer Products 74004 Installation guide

Type
Installation guide
EXPANSION JOINT TO
ENGINEER’S DETAIL
CONCRETE
BEDDING LAYER
SOIL
Site Installation Manual
Polymer Concrete Drain Systems
ACO DRAIN
Re-order DL016
2
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POLYMER CONCRETE
ACO Drain consists of a full range of
modular channels with captive grates;
Systems include catch basins, end caps,
and other accessories.
When installed correctly, ACO Drain
products are designed to withstand a
variety of loadings as classied by
EN 1433 (The only standards specically
for trench drain systems).
Getting Started
Contents
Getting Started 2
Health and Safety 3
Installation Sections 4
1. Excavation 6
2. On-site Fabrications
- Cutting channels & Tee junctions 7
- Miters, Corners, Bends & Radius 8
3. Pipe Connections 9
4. Connection with
Underground Piping 10
5. Positioning of Channels
- Patty Method 11
- Hanging Methods 12
- Installation Devices 14
6. Catch basin blanking plates 15
7. Pouring Concrete 16
8. Pavement Finishing
- Concrete 17
- Asphalt 18
- Brick Pavers 18
9. Fit / Remove Grates 19
10. Final Inspections & Maintenance 22
Polymer concrete products should be
handled with care as they can be
damaged by impact from other products,
or machinery.
Typical equipment necessary for
installation may include:
Excavating equipment
String-line and laser level
Measuring tools
Masonry drill, grinder and/or saw
Rubber mallet
Concrete - 4,000 psi recommended
compressive strength
Gloves, respirator and eye protection
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POLYMER CONCRETE
Commercial Trench Drains
Health and Safety
Polymer concrete
Products are manufactured using
synthetic resin, mineral aggregates and
curing agents.
Main hazards include:
Abrasive damage to hands.
Inhalation of dust from grinding, cutting,
or drilling.
Grinding, cutting, etc. may project small
fragments.
Gloves, eye protection and a respirator
should be worn to avoid these hazards.
Metal grates
Grates are typically made from either cast
or fabricated metals.
Main hazards include:
Abrasive damage/cuts to hands.
Inhalation of dust from grinding
or cutting.
Grinding, cutting, etc. may generate
sparks; ammable items should be
removed from area.
Gloves, eye protection, and respirator
should be worn to avoid these hazards.
Operations should be conducted away
from areas of re or explosion hazard.
Make sure arrows molded on sides
of channel all point in the intended
direction of ow (outlet point).
Male
Female
male end
(down stream)
female end
(up str
eam)
Flow direction
indicator arrow
Channel sequence
number
Only required for
QuickLok grates
Supplied
by others
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POLYMER CONCRETE
These illustrations are a guide
for typical ground conditions
only. Engineering advice
should be taken.
Refer to www.ACODrain.us for
further information.
An installed ACO Drain System
should incorporate the following:
Correct grate type.
Correct channel type and size.
Recommended grade 4,000 psi
compressive strength cement
concrete surround.
Concrete surround dimensions
are minimum dimensions and
engineering advice should be
taken to conrm appropriate for
the specic project.
Concrete surround should
typically be the same thickness
as the concrete slab.
Poor site conditions and low load
bearing pavement will require
an increase in these dimensions
to meet both vertical and lateral
loads.
Reinforcing steel may be required
within the slab and around the
trench drain - engineering advice
should be sought to determine
bar size and conguration.
For Load class F applications,
ACO recommends using the
concrete anchors offered with
PowerDrain.
See table
pg 6
See table pg 6
See table pg 6
Pavers
Subgrade
See table
pg 6
See table pg 6
See table pg 6
Pavers
Subgrade
Installation Sections
Pavers - EN 1433 Class A - F
Pavers - EN 1433 Class A - C only
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POLYMER CONCRETE
Commercial Trench Drains
See table
pg 6
See table pg 6
See table pg 6
Asphalt
Subgrade
Concrete
See table
pg 6
See table pg 6
See table pg 6
Subgrade
Concrete
Expansion
joint to
engineer’s
details
See table
pg 6
See table pg 6
See table pg 6
Subgrade
Asphalt
Concrete
Asphalt - EN 1433 Class A - C only
Concrete - EN 1433 Class A - F
Asphalt - EN 1433 Class A - F
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POLYMER CONCRETE
C. For sloped systems, excavate base
of trench to roughly follow fall of
trench run.
Ensure loose material is removed from
trench and base is well compacted.
Run string line, or laser, at nished
surface level along full length of proposed
trench run to ensure trench is installed to
grade.
In concrete pavements ensure an
allowance is made for expansion/isolation
joints, if necessary, to allow movement
due to thermal expansion/contraction.
Load Cl A B C D E F
4”
channel
4” 4” 6” 6” 8” 12”
8”
channel
4” 4” 6” 8” 8” 12”
12”
channel
4” 6” 6” 12” 12” 12”
Excavate trench to accommodate drain
system. Excavations must be made about
the center line of proposed drainage run
and catch basin.
Trench must be big enough to
accommodate each of the following:
A. Channel/catch basin width and
depth dimensions.
B. Concrete surround dimensions*.
1
Excavation
xx
ACO Drain channel
Finished surface
See table below
for recommended
dimensions
Form board if requiredTrench profile
x
10,
010, 010, 010, 010, 010, 010, 010, 010
9,
8,
7,
6,
5,
4,
3
Sloped
system
Constant
depth
system
Concrete Surround Dimensions* (x)
NOTE: Check product literature for
overall product depth. Add additional
measurement for concrete surround
from table at left.
* These dimensions are recommended
minimums only, based on recommended
4,000psi concrete. Ground conditions
will affect actual dimension required;
engineering advice should be sought.
Concrete surround should be same
thickness as surrounding slab depth.
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POLYMER CONCRETE
Commercial Trench Drains
When cutting channels and/or grates,
gloves, protective eye wear and respirator
or mask are recommended.
Cutting channels
Required to form miters, tee junctions
and non-standard lengths. Most
fabrications can be completed on site.
ACO offers a custom fabrication service
for more complex fabrications. Contact
ACO Technical Department for further
information.
Channels should be cut with a masonry or
diamond disc saw. Grates should be cut with
band saw, or similar, with suitable blade.
A 2 - part rigid resin glue (ACO Bond) can
be used to bond cut surfaces together, if
required.
If corrosive liquids are transported in
trench, joints should be properly sealed.
Ensure the sealant/adhesive used is
chemically resistant.
2
On-Site Fabrications
Tee Junctions
Tee junctions are when an opening is cut
into the side of one channel and another
channel is butted up to this opening.
All half meter channels provide molded
guide for side removal. Other channels;
mark area in channel wall to be removed
by butting channels together and marking
prole of interior of channel.
NOTE: Edge rail should be left intact
to provide additional strength and
seating for grate.
Cut opening
on the side
of the channel
Side wall cut-out
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POLYMER CONCRETE
Miters
Corners
Formed by cutting channels to required
angle and butting together.
For heavy duty applications (D-F), mitered
grates are not recommended. A tee joint is
suggested to give grate maximum support.
Channels are mitered;
grates are shown as tee joint.
Channels mitered
at 45° angle
2
On-Site Fabrications
Radius
Channels can be installed to slight curves
by leaving an acceptable gap at the
channel joints (acceptable gap to be
approved by client).
Tight curves/bends
For tight curves or bends, miter cut end of
each channel and grate to required angle.
Results in a neat nish at joint
Using half meter non-sloping channels, allows more ’segments’ to be added to the radius;
the gap between channels is reduced, or alternatively a tighter radius can be achieved.
Miter each
channel end
Acceptable gap
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POLYMER CONCRETE
Commercial Trench Drains
Channel - knockout
Stand channel upright holding outlet
end in hand to absorb impact
and prevent cracking. Using
hammer, from inside of channel,
carefully tap out required area
following around inside of symbol.
x
xx
xx
xx
xx
Knock-out symbol
Tap here
3
Pipe Connections
Removal of knockout, or cut hole:
1. Identify and mark area to be removed.
(Bracing may be necessary).
2. Material removal:
Catch Basin - cut-out
Use cut-off tool, reciprocating saw
or band saw to cut opening for
required pipe size and location.
3. Use a grinder to dress or enlarge hole
for proper pipe insertion.
4. A pipe may be tted into hole
using appropriate sealant/adhesive.
If corrosive liquids are transported
in trench, ensure sealant or adhesive
is chemically resistant.
3. Attach outlet pipe using coupler,
if required seal using appropriate
sealant/adhesive. If corrosive liquids
are transported in trench, ensure
sealant or adhesive is chemically
resistant.
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POLYMER CONCRETE
Channels may be connected directly to
underground piping via:
1. End cap outlets (horizontal outlet).
4
Connection with Underground Piping
2. Vertical knockouts (penetrations
on underside of channel).
3. In-line catch basin.
4. Catch basin.
Connecting channels to catch basins
Catch basins have guides for channel
connection at depths corresponding to
invert level of designated channel units
(10, 20, 30, 40).
In-line catch basins - cut out black end
material at required channel height. Seal
joint with exible sealant. See page 15 for
end blanking plate details, if required.
600 Series catch basins - stitch drill out
polymer concrete panel (100 systems) or
cut out black end material (200 systems)
at required height. See page 15 for end
blanking plate details, if required.
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POLYMER CONCRETE
Commercial Trench Drains
Male
As per table (pg. 6)
Female
Work away from outlet
ACO DRAIN
Concrete key
Avoid concrete/dirt at joint
5
Positioning of Channels
Start with outlet. Ensure string-line, or laser
is set at top edge of required channel height.
Common methods of positioning channels:
include:
1. Patty Method
2. Hanging Method
3. Installation Device
1. Patty Method
a) Set catch basin (or outlet channel) on
bed of concrete to required height
(see page 6 for concrete dimensions).
Connect and seal outlet pipe.
b) Using low slump concrete, create
‘patties’ at intervals to support channels.
Allow two patties per channel, spaced
such that no concrete material is
trapped in joint, creating gaps.
Note: Patties should be sized to
provide required concrete surround
(see page 6).
c) If channels are to be sealed, roughen
ends and use a exible sealant -
check chemical compatibility, if
required.
d) Lower channel vertically onto ‘patties’
and position to correct height and
alignment ensuring ‘tight’ connection
to previous channel.
e) Add concrete on top of ‘patty’ to cover
concrete ‘keys’ on side of channel - this
prevents movement, or oating, during
concrete pour.
f) Continue to lay channels until end of
run or next catch basin is reached.
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POLYMER CONCRETE
2 x 4’s (anchoring
fasteners should be
used to prevent floating)
Cross
bar
Spacers allow
concrete surface
finishing at
supports
Use shims to position
channel correctly
relative to slab
Finished height
Plywood bracing
Plywood
bracing
Threaded rod
Threaded rod
100 - L=4.64” H=0.50”
200 - L=8.58” H=0.75”
300 - L=12.52” H=0.75”
H
L
1.25”
Saw cut
2 x 4
supports
Anchoring
fasteners
to prevent floating
Spacer
5
Positioning of Channels - Hanging Methods
Retrot installations - use existing slab to
anchor supports. Alternatively, form boards
can also be used.
2.i Bolting Method - DrainLok/
QuickLok
K100, K200, K300, H100, H100K, H200K,
H300K will require a long threaded rod and
cross bar to t in the locking bar recesses.
a) Cut 2 x 4’s to length to span excavated
trench or form boards (minimum 2 per
channel - K200 & K300 will require 3 - 4).
Cut ‘spacers’ to ‘lift’ supports above
nished level. Cut bracing to t into
grate rebate.
b) Drill 5/8” diameter holes in the center
of each 2 x 4 and spacer. Drill holes in
center of bracing at 19.69” (500mm)
centers to match locking positions.
c) Tighten 5/16” x 18 threaded rod
through center of each cross bar. Fit
cross bars into channel recesses.
d) Slide bracing, spacers and 2 x 4’s over
threaded rods.
e) Lower channels into excavated trench,
adjust to required position and height.
Shims may be required beneath 2 x 4’s
to achieve required height and ensure
channels are level.
f) If channels are to be sealed, roughen
ends and use a exible sealant - check
chemical compatibility, if required.
g) Nail or anchor 2 x 4 supports securely to
slab/form boards. This ensures channels
are held securely during concrete pour.
Retrot installation
New installation
Threaded rod and bar
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POLYMER CONCRETE
Commercial Trench Drains
5
Positioning of Channels - Hanging Methods
Retrot installations - use existing slab
to anchor supports. Alternatively, form
boards can also be used.
2.ii Bolting Method - PowerLok
S100K, S200K, S300K, H100SK,
H200SK, H300SK will require M10 - 1.5
x 120mm bolts to screw into widgets in
edge rail of channel. This allows the bolt
to pass through the spacers, 2 x 4’s and
into widget nut.
a) Cut 2 x 4’s to length to span excavated
trench or form boards (minimum 2 per
channel - S200K & S300K will require
3 - 4 per channel). Cut ‘spacers’ to
‘lift’ supports above nished level.
b) Drill two 5/8” diameter holes in the
2 x 4’s and spacers - width to match
widgets in channel rail.
c) Using M10 - 1.5 x 120mm bolts with
washers, bolt 2 x 4 and spacer to
channel - do not overtighten. If using
torque wrench do not set higher than
15ft. lbs.
d) Lower channels into excavated trench,
adjust to required position and height.
Packing material may be required
beneath 2 x 4’s to achieve required
height and to ensure channels are level.
e) If channels are to be sealed, roughen
ends and use a exible sealant - check
chemical compatibility, if required.
f) Nail or bolt 2 x 4 supports securely
to slab/form boards. This ensures
channels are held securely during
concrete pour.
Widgets in edge rail
Saw cut
2 x 4
supports
Anchoring
fasteners
to prevent floating
Spacer
2 x 4 (anchoring fasteners
to prevent floating)
Finished height
Spacers allow
concrete surface
finishing
New installation
Retrot installation
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POLYMER CONCRETE
5
Positioning of Channels - Installation Devices
A clamping system that ts around the
proled end details is available to support
the channel in place and allow a single
pour if required.
Rebar is used to achieved correct height.
One device per joint is required, including
start and end of the run.
100, 200 & 300 wide versions available.
Parts are supplied with a full detailed
instruction sheet
Adjustable clamp fits
into recesses on
side of channels
Rebar allows
easy height
adjustments
1. Create required width template using
timber sheet or similarly suitable rigid
material. Diagrams can be printed
from the ACO website.
www.ACODrain.us/technical.html
2. Start at outlet. Drive #4 or #5 rebar
into ground to hold three installation
devices spaced using ACO template.
Screw installation device to rebar at
required height.
3. Set channels in position but do not
lock into position until next channel is
in place as his allows some exibility
and movement.
4. Move template and set rebar in place
- always allow two sets of rebar to be
installed before placing channels to
enable template to be moved to next
position.
5. When ready to lock channels in place,
ensure channel is positioned such
that the xed clamp ts into recess in
channel end.
6. Push adjustable clamp tight onto
other side of channel.
7. Tap metal wedge into slot to lock
adjustable clamp in place, locking
channel joint closed.
5. Repeat for additional channels.
6. Check channels are at required level -
adjust using screws on rebar.
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POLYMER CONCRETE
Commercial Trench Drains
All in-line catch basin tops and the 200mm
and 300mm wide 600 Series catch
basin tops have open end rails to allow
connection of channels both ends.
Blanking plates are supplied to prevent
concrete ingress during the concrete
pour when channel connection does not
close end rail openings. Blanking plates
match catch basin edge rail - galvanized,
stainless, or coated black steel to match
color of iron rails.
To close off the entire opening where no
channel is connecting, simply push down
over the polymer concrete bridge.
Catch Basin Blanking Plates
6
Push blanking plate down over
the polymer concrete bridge
Where a channel is connecting into a
Series 600 catch basin the blanking plate
can be cut, removing the center where the
channel connects.
Blanking plate cut down to
fit channel opening.
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POLYMER CONCRETE
Concrete should be poured evenly (both
sides of channel) and carefully to avoid
dislodging channels. A wand type concrete
vibrator should be used to ensure concrete
distributes evenly around channels.
If ‘cold joints’ are a concern, engineering
advice should be sought to determine
single pour procedure.
Channel Anchors
For Load class F applications, ACO
recommends using the concrete anchors
offered with PowerDrain. Metal anchors are
attached through punched out hole in edge
rail - see Technical Bulletin for details.
Channel Bracing
To prevent channel wall and joints from
distortion by weight of concrete, grates
or 3/4” plywood sections (cut to create
a snug t) should be placed in the grate
rebate of channel.
If grates are used, they should be suitably
protected from concrete contamination
during concreting (wrapped in plastic
or masking tape) and should be laid to
bridge channel joints to aid alignment.
Shims (or washers) should be placed
along one side to maintain a clearance
gap.
Concrete Pour
If using closing/outlet end caps with
channels 1-15 remove unused spigot to
ensure sufcient concrete coverage.
To prevent concrete from lling channel
body, cover open areas with plywood or
similar. (Bracing should sufce).
Recommended that concrete have
compressive strength of 4,000 psi.
If using hanging method, and channels
are securely in position, rst concrete
lift should come approximately 2 inches
(50mm) up sides of channels.
Once rst lift has hardened, remaining
concrete surround can be poured.
7
Pouring Concrete
Shim
Second lift
First
lift
Anchor
Screw
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POLYMER CONCRETE
Commercial Trench Drains
Finished concrete
to have slight
slope down to
channel
Approx.
45°
Concrete
1/8”
Grating
Transverse
joint
Original slab
Align with channel joint
Expansion
joint
Pavement Finishing - Concrete
To nish installation, trowel concrete at
and taper down to channel edge. The
top of adjacent pavement must be above
the grate level (approximately 1/8”), this
ensures all liquids drain into the channel.
Once concrete has cured 24 hours,
remove bracing and/or grate protection.
Fit grates - see page 19/21.
Expansion joints
Transverse joints (perpendicular to the
channel) are required to prevent surface
cracking in the slab. Such joints should
be positioned at channel joints to prevent
channels from cracking. If such spacing is
not possible, a cut must be made at the
appropriate location through the channel
and sealed with exible sealant.
Longitudinal expansion/isolation joints
should be continuous and exible. They
must be provided between the concrete
surround and surrounding slab and may
be varied to suit concrete surround width
by up to a meter (3 feet) from the channel.
If the joint is dowelled, debonding should
be provided. ACO recommends seeking
engineering advice.
8
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POLYMER CONCRETE
Pavement Finishing - Asphalt
For applications where asphalt can be
applied directly up to channel edge, see
appropriate channel/installation detail.
ACO recommends for applications over
Class C a full concrete surround be used.
See page 6 for concrete haunch details.
CAUTION: To prevent damage to
channels and grates, protect channel
between concrete pour and application of
asphalt and when rolling asphalt.
Asphalt must be above grate level by
approximately 1/8”, this ensures all liquids
drain into channel.
Once pavement is nished, remove
bracing and/or grate protection. Fit grates
- see pages 19/21.
Pavement Finishing - Brick Pavers
For applications where brick pavers can
be installed directly up to channel edge,
see appropriate channel/installation detail.
ACO recommends for applications over
Class C a full concrete surround be used.
See page 6 for concrete haunch details.
Brick pavers adjacent to channel MUST
be fully bonded to concrete haunch. This
prevents movement of bricks and possible
damage to channel. Subsequent pavers
can be bedded on compacted sand.
Bricks must be above grate level by
approximately 1/8”, this ensures all liquids
drain into channel.
Once pavement is nished, remove
bracing and/or grate protection. Fit grates
- see pages 19/21.
Concrete
1/8”
Grating
First course bonded
to concrete haunch
Concrete
1/8”
Grating
Approx.
45°
Finished asphalt
to have slight
slope down to
channel
Base
Course
8
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POLYMER CONCRETE
Commercial Trench Drains
9
Fitting/Removing Grates
DrainLok Grates
1. DrainLok does not require a locking
bar - clips in the grate t into recesses
in the steel edge rail to hold grates
securely in place.
2. To install grate, align clips in underside
of grate with recesses in edge rail. Push
down/stand on grate until clicks into
position.
3. To remove rst grate, insert removal
tool under grate bar, pull up sharply.
Subsequent grates can be removed by
hand - Grip end of grate and lift sharply.
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POLYMER CONCRETE
QuickLok Grates
1. Fit QuickLok bar in channel wall
recesses by rotating clockwise.
K100 - Use hammer to tap into place,
so that serrated ends grip in recess.
K200/K300 - Use plastic safety clip
to hold bar in place.
2. To install grate, align stud directly over
locking bar. Push down/stand on grate
until clicks into position.
3. To remove rst grate, insert removal
tool under grate bar, pull up sharply.
Subsequent grates can be removed by
hand - Grip end of grate and lift sharply.
4. To remove K100 bar, insert screwdriver
into hole at end of bar - lever back
serrated section to loosen. K200/K300
- remove plastic clip to remove bar.
9
Fitting/Removing Grates
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Aco Polymer Products 74004 Installation guide

Type
Installation guide

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